Barrier Guardrail Panel Assembly

ABSTRACT

The present application provides a barrier guardrail assembly comprising: a barrier guardrail panel having a top horizontal rail and a vertical rail on each of left and right edges of the panel having an upward extending tab positioned generally at the top end of the vertical rails, and which extends beyond a top edge surface of the horizontal rail; and one or more vertical support posts, each comprising a shaft having a tab bracket having an optional tab gusset which is engageable with the upward extending tabs of the panel, first and second segments engageable with and for retaining the horizontal rail, and a base plate having one or more vertical guide members forming a channel for restraining a bottom edge of the barrier guardrail panel in position when assembled with the vertical support posts.

CROSS REFERENCE APPLICATIONS

This application is a non-provisional application claiming the benefits of provisional application No. 63/247,383 filed Sep. 23, 2021, which is hereby incorporated by reference for all purposes.

FIELD

The present application generally relates to fences, barriers and related equipment. More particularly, the present application relates to a barrier guardrail post and panel assembly.

BACKGROUND

Fences and related barriers have numerous applications, more typically for protecting and/or preventing or restricting access to an enclosed or restricted area, or for offering protection to people from falling off the edge of higher levels of building structures. While more permanent fencing is ideal to enclose fixed locations or properties, they can be laborious to assemble, and can require extensive materials (often including concrete and heavy digging machinery), planning or surveying, and are expensive to build and maintain. They also need to be more rigid and follow more strict regulations. Temporary fencing, in the form of removable barriers, is particularly useful in locations where protection is required for limited applications and for a specific period of time or purpose, such as during an event (e.g. a concert or other public gathering), or to direct foot or vehicular traffic on roadways or walkways. Fencing to enclose an area at ground level typically needs to be much taller than in other temporary applications. Because of their temporary nature, many of these types of barriers and fences are often of reduced quality and may not meet high safety standards. Further, clips, hooks and other external attachments may be required in existing guardrail assemblies, which can be easily damaged and thus could compromise their safety and integrity.

On construction sites, guardrail panels and similar barriers are important for defining work areas which often contain dangerous activity and offer a higher risk of personal injury. These areas may require workers having particular safety training. However, many of the barriers currently used are not made of long-lasting durable materials (e.g., wood or other natural products that are non-uniform and can degrade significantly over time), and built in such a way that may not be suitable in accordance with health and safety building codes. Further, the fluid nature of many building sites requires barriers and other fencing to be assembled easily and more quickly, and possibly moved from location to location, and this is impeded by heavy or awkwardly constructed barriers. Guardrail panels are regularly removed to access the edge of the floor slab at a construction site. The re-installation of existing panels can be complicated or time-consuming, or may require additional materials (tie-wire is sometimes used), which can be a deterrent to properly installing and re-installing appropriate barriers in these locations.

Barrier-type fence assemblies are known in the art (see, for example, US Patent Application Publication No. 20180371790 to Westphal; US Patent Application Publication No. 20010045555 to Ross; US Patent Application Publication No. 20190234103 to Fakhari; U.S. Pat. No. 5,779,227 to Childers et al.; U.S. Pat. No. 3,767,167 to Rasmussen; Canadian patent application CA 2028253 to Van Lien et al.). Existing barrier fence assemblies are typically fixedly secured (e.g. drilled, screwed, nailed, clipped, tie-wired etc.) directly to the shaft of the post. Adjacent fence panels may be connected via a common connecting vertical shaft with a pole or key, but often require a type of “lock and key” interlocking or “deadbolt” arrangement, hooks, pins, or other retaining elements on the panel and/or a base support, requiring more precise tooling of the component parts, and proper alignment and placement by a user. These can be tedious, more difficult to assemble properly and safely, and are easily damaged, all of which can lead to lost revenue and manpower hours.

Therefore, there is a need for permanent or temporary barriers which can be more easily assembled and transported, are lightweight and with minimal components needed for installing them safely and securely, particularly at construction sites.

This background information is provided for making information available which is believed by the applicant to be of possible relevance to the present application. No admission is necessarily intended, nor should be construed, that any of the preceding information constitutes prior art against the subject matter presented herein.

SUMMARY

An aspect of the present application is to provide an improved barrier guardrail panel assembly.

In accordance with one aspect, there is provided a barrier guardrail assembly comprising a barrier guardrail panel having a top horizontal rail, and a vertical rail on each of left and right edges of the panel, each vertical rail having an upward extending tab positioned generally at the top end of the vertical rails, and which extends beyond a top surface of the horizontal rail; and one or more generally vertical support posts, each comprising a shaft having an upper section and a lower section, the shaft having a tab bracket in the upper section which has: an optional gusset member which is engageable with the upward extending tabs of the panel to restrict undesired horizontal movement; a first segment member connected at one end to the shaft and at another end to a downward extending second segment which is engageable with the horizontal rail for retaining the horizontal rail; and a base plate in the lower section having one or more vertical tabs forming a channel for restraining a bottom edge of the barrier guardrail panel in position when assembled with the vertical support posts.

Advantageously, the barrier guardrail panel assembly of the present application can be assembled with no additional hardware required to attach a panel to a vertical support post. Minimal supplemental hardware may optionally be used to tie panels in place, such as to reduce any clanging noise that may occur by excessive vibration or movement of the panels caused by the wind or surrounding construction (such as in outdoor installations). Further, the vertical support posts may typically only require minimal supplemental hardware to install into a fixed concrete slab. The assembly components, particularly the one or more vertical support posts and associated panel(s), can be transportable to different locations of a worksite as needed, or the vertical support posts can be fixedly secured at a location, such as secured to the concrete slab with concrete anchor bolted directly into the concrete slab or secured to a cast-in insert embedded in the concrete slab, for more permanent or semi-permanent uses. The barrier guardrail assembly as described herein is particularly suitable for use on concrete slabs, such as in the construction of high rise structures.

The barrier guardrail panel assembly is relatively lightweight and portable, and can be readily installed, more typically requiring only a single person to assemble. In site locations having pre-cast or drilled-in anchor attachments dedicated to the vertical posts, the panels and vertical support posts that make up the assembly can be more easily positioned into place. This facilitates proper installation of the barrier guardrail panel assemblies and may contribute to a more secure work environment.

In some embodiments, the panels are positioned within the assembly with a degree of flexibility to allow the panels to slide slightly (or more significantly as needed) from side to side, allowing them to overlap. This permits the panels to cover smaller openings, which may not be possible with other existing more permanent barrier or fence structures. The amount of horizontal movement is typically dependent on the distance between the two vertical posts supporting a given panel. Indeed, in certain embodiments, a panel would significantly or almost completely overlap an adjacent panel when the respective vertical posts are sufficiently close together. Further, the barrier guardrail panel assembly components can be easily stored in crates or other containers that can be engineered to allow them to be lifted by crane onto the building structure, and can be stored together in bulk for easier storage, transport and assembly.

Further, unlike existing barrier guardrails or more permanently-constructed fences and the like, the present barrier guardrail panel assembly reduces the need for moving or locking parts or additional hardware. For example, clips, hooks and other external attachments are not required to position and secure the barrier guardrail panel with the vertical support posts in its simplest form. A user needs only to lift the lightweight panel and position the upper horizontal rail of the panel under the top brackets of the vertical support posts, such that the upwardly extending tabs are positioned on the opposite sides of the tab bracket members. Conveniently, the panels may be slid from side to side (i.e., horizontally) within the vertical support post as desired to cover up as much or as little space to be protected by the panels, but are prevented from completely sliding out of the track on the base of the support post by the upwardly extending tabs. If the posts are much closer together than the width of the panel, the upward extending tabs will typically not abut the gusset of the tab bracket (or the first (short) segment member if no gusset is present), unless moved into contact with either of them. However, when the upward extending tabs abut the opposite sides of the bracket, undesirable sideways sliding right out of the panel and post assembly is prevented. To remove the panel, the user simply lifts the panel so that it clears guide members on the base plates of the vertical posts, and then swings the panel towards them to clear the posts. By allowing a user to assemble the barrier guardrail panel assembly more quickly and easily, compliance with safety and construction standards may be more readily achieved. In addition, no particular expertise is required to assemble the barrier guardrail assembly, meaning that the assembly is not necessarily restricted to specifically-trained personnel on a construction site.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a perspective view of one embodiment of a panel of the present barrier guardrail panel assembly.

FIG. 2 shows a front elevation view of the panel of FIG. 1 .

FIGS. 3A and 3B show perspective views of two other embodiments of panels of the present barrier guardrail panel assembly in isolation. FIG. 3A shows a panel with a top reinforcement brace on the upper horizontal rail and FIG. 3B shows a panel without the reinforcement brace.

FIGS. 4A-D shows one embodiment of the vertical support post. FIG. 4A shows the post in front perspective; FIG. 4B shows the post in rear perspective; FIG. 4C shows a front facing view of the post; and FIG. 4D shows a side view of the post

FIG. 5 shows a top view of the vertical support post of FIGS. 4A-D.

FIG. 6 shows a close up of an embodiment of a tab bracket on a vertical support post.

FIG. 7 shows a close up of an embodiment of a base portion (including base plate) of the vertical support post.

FIGS. 8A-C illustrate one attachment of the vertical support posts to a concrete slab. FIG. 8A shows a support post being attached through a hole in the baseplate directly to a concrete slab using a concrete anchor. FIG. 8B shows an example of a support post with a cast-in insert and attachment of a baseplate to the cast-in insert embedded in a concrete slab (not shown), as described herein. FIG. 8C shows an installation of the cast-in coil anchor into an anchor sleeve in the cast-in insert of FIG. 8B.

FIGS. 9A and B show an example of a method of installing the barrier guardrail panel with the vertical support posts to form a barrier guardrail panel assembly as described herein; FIG. 9A shows the panel in the process of being inserted (or removed), while FIG. 9B shows the panel and vertical support posts as assembled together in the barrier guardrail assembly.

FIG. 10 illustrates an installation of a second barrier guardrail panel with the vertical support post to form the barrier guardrail assembly comprising two adjacent panels.

FIG. 11 illustrates removal of a guardrail panel from the barrier guardrail panel assembly.

FIGS. 12A-D show close ups of the tab bracket on the vertical support post with two adjacent panels being assembled therewith. FIG. 12A shows a close up of the tab bracket with the upper tabs abutting the optional gusset of the tab bracket, while FIG. 12B shows a close up of the tab bracket with adjacent panels overlapping. FIG. 12C shows a perspective view of the panels and vertical support posts of FIG. 12B being assembled, and FIG. 12D shows a close up of the tab bracket of FIG. 12B, fully assembled.

FIGS. 13A and B show a close up of the barrier guardrail panel being inserted into the channel in the base plate of vertical support post, in assembling the barrier guardrail panel assembly (with a first panel already inserted). FIG. 13A shows two adjacent panels in general close proximity, while FIG. 13B shows two adjacent panels overlapping.

FIG. 14 shows a close up of the tab bracket with a barrier guardrail panel inserted in the assembly.

FIG. 15 shows a close up of the tab bracket with two adjacent barrier guardrail panels inserted in the assembly.

FIG. 16 shows a prospective view of two adjacent panels overlapping in the assembled barrier guardrail assembly.

FIGS. 17A and B show an example of a corner arrangement of panel assemblies.

DETAILED DESCRIPTION

A barrier guardrail panel assembly as described herein generally comprises a barrier guardrail panel having a vertical rail at each of left and right edges thereof and a top horizontal rail therebetween; and corresponding generally vertical support posts for engaging with the barrier guardrail panel at the corresponding left and right vertical rails. FIGS. 1, 2 and 3A-3B show embodiments of a barrier guardrail panel 100 as used in the present assembly. FIGS. 4A-4D show embodiments of vertical support posts, 300 that are used in combination with the panel to form the barrier guardrail panel assembly. It will be appreciated that additional components may be added to the assembly and/or to the panel and/or vertical support post as desired, depending on the use. However, in normal use, one assembly “base unit” can be constructed by simply using a barrier guardrail panel and two vertical support posts, one towards or at either side edge of the panel, as described herein. Additional vertical posts and panels can be added (i.e. “interlocked”) at either edge of this base unit assembly, extending the assembly in any number of assembly base units, and in either direction from the base unit, as desired. Further, one or more of the vertical support posts may be self-supporting and/or releasably fixed to a surface beneath the base plate of the posts into a concrete slab, for example; thus, the barrier guardrail panel assembly (or any part of the whole assembly, when a plurality of interlocking assembly units are used) can be portable or in a fixed location, either temporarily or more permanently as needed. In addition, as illustrated in FIGS. 17A and 17B, the barrier guardrail panels can be positioned at corners of the concrete slab, such that only a minimal gap is present between the rail of the guardrail and a corner adjacent (i.e., perpendicularly facing) panel assembly.

In certain embodiments, the components of the barrier guardrail panel assembly are made from carbon steel. Various grades of steel can be used for various components. Steel is typically preferred over other materials such as traditionally-used wood, which can degrade over time. However, other durable metals or materials may be used. Further, the assembly may be treated to maximize longevity (e.g., painted, powder coated or galvanized, for example) or to provide additional structural integrity.

As best shown in FIGS. 1, 2 and 3A-3B, a barrier guardrail panel 100 is generally rectangular in shape. The panel 100 comprises two substantially vertical rails 5 a, 5 b which form left and right edges of the panel, respectively, and a bottom horizontal rail 45. A top horizontal rail 1 spans the length between the two vertical rails 5 a, 5 b. (In one embodiment, shown in FIG. 3B, the vertical rails 6 a and 6 b comprise a channel along the vertical length of the rails). The top horizontal rail 1 is securely connected at its ends 72 a, 72 b to respective top ends 76 a, 76 b of vertical rails 5 a and 5 b. As used herein, “securely connected” or “connected”, unless otherwise qualified, may refer to a connection by any suitable means to securely connect (either releasably or preferably permanently) two or more members or components of the assembly; non-limiting examples include bolting or welding, but other means of securing may be used—alternatively, the two or members may be integrally molded together. In certain embodiments, the ends 72 a, 72 b of the top horizontal rail 1 are securely connected to the top of the top ends 76 a, 76 b of the vertical rails 5 a, 5 b, such that each end face (not shown) of the top horizontal rail is exposed for securely connecting with the upper tabs 2 a, 2 b, described in greater detail below. In this regard, the end faces of the top horizontal rails are typically substantially flush with each respective exterior surface of the vertical rails 5 a, 5 b (e.g., end 72 a would ideally be flush with exterior surface 20 of vertical rail 5 a). In some embodiments, the top horizontal rail 1 may also comprise an optional but preferred reinforcement brace 12 for added support and/or to facilitate handling of the barrier guardrail panel during installation and removal. In some embodiments, a date plate (not shown) may be provided on panel, on which is provided further information or indicia as desired.

In some embodiments, a toeboard 30 is provided which forms at least a part of the bottom edge of the panel 100 (or can be a thin plate welded to a barrier material such as mesh 50 of the panel) and is securely connected at its ends 42 a, 42 b, with respective bottom ends 46 a, 46 b of the vertical rails 5 a, 5 b and/or with the bottom horizontal rail 45; alternatively, the toeboard may be integrated in single construction with all or part of the rest of the panel 100. The toeboard 30 is typically a solid member, such as made of metal, wood or some other durable material that may protect against falling debris Ideally, there is only a minimal gap (e.g. no more than about ¼″) underneath the bottom edge of the panel. Ideally, the toeboard 30 spans the entire distance between the interior panel-facing surfaces of vertical rails 5 a, 5 b, thus providing uninterrupted horizontal coverage where adjacent panels overlap. In this way, for example, a face of the toeboard may or may not be generally flush with faces 47 a, 47 b of the respective vertical rails 5 a, 5 b; however, they are ideally positioned effectively perpendicular to and centered on interior surfaces 46 a and 46 b (as the toeboard is typically welded to a mesh 50 or other similar barrier material which is centered on surfaces 46 a and 46 b). As such, the panels can be oriented with either face towards the user. Further, the bottom edge 44 of the bottom horizontal rail 45 (or the bottom of the toeboard 30 if the panel does not have a fixed bottom horizontal rail) should be generally flush with the bottom surfaces 17 a, 17 b of vertical rails 5 a, 5 b to minimize the gap space between the panel and the ground surface and to sit flat on the base plate(s) of the vertical support post(s). A toeboard gusset (not shown) may be provided within the toeboard 30 to provide additional reinforcement to the toeboard. In another embodiment, the toeboard is a thin plate welded to the mesh of the panel.

The barrier guardrail panel 100 comprises a front and a back facing, which is typically a barrier material such as a wire grid or mesh forming a semi-permeable barrier, and situated between the vertical rails 5 a, 5 b, and between the top horizontal rail 1 and the bottom horizontal rail 45 (or toeboard 30). A facing is shown in FIGS. 1, 2 and 3A-3B. The facing barrier material, such as mesh 50, may be made of any suitable durable material, typically metal (such as aluminum, iron, or preferably steel, and preferably treated (e.g. painted, powder-coated, galvanized etc.) or otherwise reinforced, etc.), such that it is fixed between the two vertical rails 5 a, 5 b and centered on the panel to maintain its integrity. The facing may comprise one or more layers; ideally, however, a facing is selected which keeps the barrier guardrail panel lightweight while still providing a sufficient barrier of protection to users on either or both of the front and back facing of the panel; prevents tools and other debris from falling from or off the building to the unprotected exterior; and allows for at least some air to pass through such that it renders the panel less susceptible to being blown away or blown over by high winds. Typically, the barrier guardrail panel assembly is more ideally suited for use in construction settings, such as at the edge of a concrete slab in building, where a user would more typically be on the inside (i.e. side further away from an edge of the concrete slab), unless wearing a safety hardness and/or tied to a separate anchor in the concrete slab or other part of the building structure to prevent falling.

The barrier guardrail panel 100 comprises one or more upper tabs 2 a, 2 b extending from the top end of the barrier guardrail panel. In the exemplary embodiments shown in FIGS. 1, 2 and 3A-3B, the upper tabs 2 a, 2 b are securely connected to the exterior surfaces (such as surface 20) of the respective vertical rails 5 a, 5 b at their respective top ends 76 a, 76 b, as well as securely connected to the top horizontal guardrail 1 at ends 72 a, 72 b (in some embodiments, the upper tabs may be adjustable, typically up or down, as needed, and fixed into a more suitable position, but are more typically of fixed dimensions). The top edge of each upper tab may be more flat (as shown in FIGS. 1 and 12A) or more rounded (as shown in FIGS. 3A and 12B-D), as desired. In certain embodiments, the upper tabs are each positioned such that at least a portion thereof overlaps an exterior face of the top ends of the vertical rails and horizontal rail to ensure flush contact with both the top horizontal rail and each vertical rail. An upward portion 80 a, 80 b of each upper tab 2 a, 2 b extends above the top surface of the top horizontal rail 1 and is of sufficient length to permit adequate engagement of each upward portion of each upper tab with the upper tab bracket of each respective vertical support post. In other embodiments, the upper tabs may be located at other locations on the barrier guardrail, but should preferably be near the ends of the top horizontal guardrail; for example, the upper tabs may be slightly offset from the ends, or located directly within either the top horizontal rail or vertical rail(s). Further, the upper tabs are shown as flat members; this is ideal to provide increased surface area contact between the upper tabs and the tab bracket (e.g., such as, in certain embodiments, when the upper tabs abut the tab gusset 207 if present, or the short segment 220, as described herein). However, any suitable shape may be contemplated, provided that at least an upward portion of the upper tabs extends above the plane of the top horizontal rail to ensure that contact surface area is available. In other words, the upper tabs should be tall enough to engage with the upper tab gusset (if present) or short segment of the vertical support posts if the panel is being slid sideways—this prevents the panel from sliding right out of the post assembly. As best illustrated in the embodiment shown in FIG. 12A, where the vertical support posts (one shown) are at or near their widest permissible distance from each other, the panels are inserted such that the upper tabs abut right up against each gusset on each vertical support post tab bracket. In this scenario, the upper tabs should ideally be short enough that when the panel is raised for removal from the vertical support posts, it is less likely for the tabs to undesirably engage with the underside of the short segment 220, which would prevent or complicate the removal of the panel therefrom.

Panels may be any desired height and width, or as required by local regulations. In one embodiment, the panel has a height of about 107 cm (or about 42-43″) from the upper edge of the top horizontal rail to the lower edge of the bottom horizontal rail, and about 102 cm (about 40-41″) from the lower edge of the top horizontal rail to the top edge of the bottom horizontal rail. Further, in one embodiment, the panel has a width of about 254 cm (about 100″) between the outside edges of the left and right vertical rails of the panel, and about 249 cm (about 98-99″) between the inside edges of the left and right vertical rails. As shown in FIG. 3A, a reinforcement brace 12 may be added to the top horizontal rail to strengthen the top rail of the panel. In certain embodiments, the total length of the upper tab (top to bottom) is typically about 96 mm, of which the distance between the top edge of the top horizontal rail and the top edge of each upper tab, when positioned on the panel, is about 46 mm.

FIGS. 4A-D illustrate embodiments of a vertical support post used with the barrier guardrail panel as described herein. The support post 300 comprises a generally long vertical shaft 302, typically hollow or solid cylindrical or square/rectangular cylindrical (e.g. cuboid, rectangular cuboid, etc.), but any hollow or solid cross-sectional shape may be contemplated. The shaft has an upper section generally shown at 204 and a lower section generally shown at 206. FIG. 4C shows a front facing view (towards the user assembling the panel assembly). FIG. 4D shows a side view. FIG. 5 shows a top bird's eye view of the vertical support post of FIGS. 4A-D.

Vertical posts may be constructed of any suitable materials, and ideally should be constructed in accordance with occupational health and safety requirements for temporary railings as required based on jurisdiction. Ideally, all steel components may be hot dip galvanized after welding and fabrication are complete.

At or near the top end 217 of the upper section 204 of the shaft 302 is located a tab bracket 208, comprising a first, horizontal segment 220 (herein referred to as a short segment), a second, vertical segment 222 (herein referred to as a long segment), and an optional tab gusset 207 shown in greater detail in FIG. 6 . In this embodiment, these segments of tab bracket 208 are generally L-shaped comprising the short segment 220 and the long segment 222. In the embodiments shown particularly in FIGS. 4A, 4B, 4D and 6 , the short and long segments are generally planar; however, other shapes may be contemplated. The short segment 220 extends generally perpendicularly from an inside surface 312 of the shaft 302. The tab bracket 208 is securely connected to the shaft 302 at a proximal end of the short segment 220 (or can be made integrally molded with the shaft). Ideally, the width of the proximal end of the short segment is less than the width of the inside surface 312 of the shaft portion to which it is connected. The distal end of the short segment 220 meets one end of the long segment 222 at vertex 224 of the L-shaped tab bracket 208. This long segment 222 extends generally downward, away from the vertex 224, and is generally parallel to the shaft 302. A bracket pocket 225 is thus defined by the shaft, short segment (or, if a gusset is present, by the bottom of the gusset) and long segment.

The lengths of either the short segment 220 or long segment 222 of the tab bracket may vary or be of the same length, and either of the segments may be longer than the other. However, the length of the short segment should ideally be of a length which is equal to, at minimum, the width (i.e. front to back) of at least one and preferably two upper tabs (such as 2 a, 2 b shown in FIGS. 1, 2 and 3A-3B) of the barrier guardrail panel to be included with the barrier guardrail panel assembly, plus at least a small amount of “give” to facilitate the addition and removal of the barrier guardrail from the vertical support post. This “give” permits slight movement of the panels from front to back for this purpose.

Further, the length of the long segment 222 should ideally be of a length to define a bracket pocket 225 sufficiently deep enough to allow the top horizontal rail (such as top horizontal rail 1 as shown in FIGS. 1, 2 and 3A-3B) of the barrier guardrail panel, to fit within it and permit contact of a front-facing surface 3 of the top horizontal rail to engage with the long segment 222, thus preventing the barrier guardrail panel from falling forward and becoming undesirably disengaged from the vertical support post when in use. Again, a small amount of “give” allows for convenient insertion and removal of the panel from the assembly, but excessive give may result in undesirable rattling or banging of the components, particularly in high wind settings.

A typical embodiment of a tab gusset 207 is shown in FIG. 6 . In one embodiment, the tab gusset 207 is a generally flat rectangular plate, made of metal or other durable material. The tab gusset 207 is positioned at one end, typically near the top end of the bracket pocket 225 (and, thus, towards the top end 217 of the shaft 302) and connected to adjacent components on one or more, preferably two or more, and more preferably three edges: a back edge 280 is connected to the inside surface 312 of the shaft 302; a top edge is connected to at least a portion of an underside surface of the short segment 220 of the tab bracket 208; and a front edge is connected to a portion of a back surface of the long segment 222 of the tab bracket 208. The tab gusset 207 should have a sufficient surface area to allow for maximal degree of contact with the upper tabs when the tabs engage with the tab gusset; thus, the contact area of the tab gusset should be sufficient to adequately hold the panel in place when the panel is shifted horizontally, to prevent it from undesirably sliding out of the assembly, while readily permitting placement and removal of the panels on the vertical support posts. The portion of the long segment 222 connected to the tab gusset 207 (i.e., the height of the tab gusset) should be sufficiently less than the entire length of the long segment 222 to ensure, as stated above, that a portion of the long segment 222 is available to engage with the top horizontal guardrail 1 of the barrier guardrail panel to prevent the panel from undesirably falling forward in use; however, a small amount of “give” in the forward-backward direction to facilitate placement and removal of the panels, but not as much such that the panels clang with tab bracket in high wind environments. Otherwise, if no tab gusset is present, the upper tabs on the panel should be long enough to be engageable with the short segment 220, to prevent the aforementioned undesired horizontal movement.

Thus, in one or more embodiments, the tab gusset, if present, is ideally securely connected to three of: the shaft, the first (e.g., short or upper) segment, and the second (e.g. long or lower) segment, to provide a more stable engagement of the tab bracket 208 with the upward extending tabs 2 a, 2 b of the panels.

FIGS. 5 and 7 illustrate one embodiment of the base plate. The support post 300 comprises a base plate assembly 333 comprising a base plate 230. The base plate 230 is securely connected to the end of the lower section 206 of the shaft 302. The shaft 302 may also be inserted into a retaining hole (not shown) and securely connected to the base plate in this way. The base plate assembly 333 comprises one or more (typically two) panel guide members 210 a, 210 b fixed on a top surface 236 of the base plate 230. The panel guide members 210 a, 210 b serve as restraints to keep the panel in place once inserted, and for forming a base plate channel 212 generally between the inward-facing ends of each of the guide members and the shaft. Therefore, the panel guide members should ideally be spaced from the shaft such that the channel 212 is deep enough to accommodate the front-to-back depth of at least one (preferably two) barrier guardrail panel(s) to be positioned therein. The panel guide members 210 a, 210 b can be any desired height; however, they should be no more than a maximum height such that a panel is permitted to be inserted and positioned with the vertical support post in the barrier guardrail assembly, while having a minimum height sufficient to retain the bottom of the panel in the channel 212 and prevent the bottom of the panel from undesirably or unintentionally swinging out. Guide members which are too tall may prohibit positioning of the barrier guardrail panel therein because such would prevent the top part of the panel from being properly inserted into, and engaging with, the bracket pocket 225 in the tab bracket 208 of the support post. The base plate may also optionally comprise one or more base plate gussets 214 a, 214 b, 214 c which are securely connected to both the base plate and at the bottom end of the shaft (such as at left, right and rear locations of the shaft 302 which do not interfere with the placement of the panel within the channel 212), for added reinforcement and to help maintain the shaft in an upright position.

The base plate 230 may also comprise one or more retention holes 216 extending through the base plate from the top surface 236 through the bottom surface thereof. The hole(s) allows for securely connecting the base plate of the vertical support post to a fixed member (such as a wood or metal board, concrete floor, or other fixed surface) for added stability, as needed. As shown in FIG. 8A, the post can be anchored directly into the concrete ideally by means of a single hole 324 drilled into the concrete, with an approved concrete anchor 325 bolted through a single hole in the post base plate and into the hole in the concrete. This is particularly advantageous over existing post assemblies which typically require more than one anchor. In another embodiment, such as illustrated in FIGS. 8B and 8C—particularly useful in conditions where drilling into concrete is not possible to secure the support post (e.g. when the concrete is embedded with pre-tensioned cable)—a cast-in insert 331 may be cast-in or embedded into the concrete (i.e. a cast-in insert is attached to the formwork before the concrete is poured) for receiving the anchor. Once the concrete is cured, the post is attached to the anchor sleeve by the cast-in coil anchor 322 into an anchor sleeve 330 (typically threaded) to receive the cast-in coil anchor 322. This is particularly advantageous over existing post assemblies which do not allow for use of a cast-in insert. The top of the sleeve is flush with the surface of the concrete. The vertical support post is attached thereto by inserting a cast-in coil anchor 322 through the hole in the base plate 230 and threading it into the sleeve. The insert comprises one or more anchor feet 320 a-d, which help keep the cast-in insert upright while concrete is being poured. Other methods to attach the support post to a fixed surface may be contemplated. However, the concrete anchor provided herein is ideal because most posts don't allow for this type of cast-in insert anchorage.

FIGS. 9A-9B and 10-13 show an example installation of the barrier guardrail panel assembly. In FIGS. 9A-9B, which show the installation of one panel within two vertical support posts, a user first positions the two vertical support posts, left and right, on a surface (preferably flat surface, such as a concrete slab), such that they are separated by a distance approximately equal to or, preferably less or slightly less than, the width of the barrier guardrail panel(s) to be used (although any suitable separation distance of vertical support posts which is less than or equal to a panel width may be contemplated). In other words, two vertical posts should be positioned such that they are spaced apart from each other at a distance no greater than a width of the barrier guardrail panel between the two vertical rails, so that the panel can have sufficient engagement with the vertical posts to be retained therein.

The posts may also be separated by a closer distance as required by the span requiring protection by the guardrail. The vertical support posts may be anchored to the surface with a concrete anchor or with a cast-in coil insert as described above. With their hands, the user then grabs the barrier guardrail panel (such as the top horizontal rail, or by the mesh, a handle if such is provided), lifts the barrier guardrail panel, and inserts the top horizontal rail 1 underneath the tab bracket, such that the top horizontal guardrail is positioned within the respective bracket pockets 225 of each vertical support post (i.e., between the face 312 of the shaft 302 and the downward long segment 222 of the tab bracket 208, as well as below the tab gusset 207). Each respective upper tab 2 a, 2 b of the barrier guardrail panel should be positioned outside of the respective tab bracket—for example, the left upper tab (shown as upper tab 2 a in FIGS. 1, 2 and 3A-3B) should be positioned to the left side of the vertical support post tab bracket of the left vertical support post, and the right upper tab (shown as upper tab 2 b in FIGS. 1, 2 and 3A-3B) should be positioned to the right side of the vertical support post tab bracket of the right vertical support post, based on the view of the user facing the barrier guardrail panel assembly. In this way, horizontal movement (i.e. left to right) of the barrier guardrail panel is restricted based on the distance between the left and right vertical support posts. Ideally, the panels can be used to cover any suitable distance between two vertical support posts, but horizontal movement of either end of the panels is controlled so as to prevent the panel from sliding right out of position (i.e., disengaged from the vertical support posts). This is because the left and right upper tabs engage with the tab gusset 207 when the panels are slid horizontally, and when the tab gusset is sufficiently long enough (i.e., extends downward) to engage with the upper tabs in this position; additionally, the respective upper tabs 2 a, 2 b should be sufficiently long enough to engage with at least a portion (preferably a substantial portion) of the tab gusset 207, if necessary, once installed. Some forward and backward movement may be allowable to provide some “give”, but ideally is minimized to prevent the panels from undesirable front-to-back movement. Further, it is the front surface 3 of the top horizontal rail that should substantially engage with long downward segment 222 of the tab bracket to prevent the panel from falling forward once installed.

Once the top portion of the panel (including the horizontal rail and respective upward tabs) is placed within bracket pocket, the user then swings the bottom portion (i.e., the bottom horizontal rail 45, and including the toeboard 30) of the panel forward, towards the lower section 206 of each shaft of each support post. The panel is lifted slightly within the bracket pocket such that the bottom edge 44 of the bottom horizontal rail 45 of the panel (and associated toeboard) can clear the guide members 210 a, 210 b on the base plate 230. Once cleared, the bottom portion of the panel is lowered into the channel 212 between the guide members 210 a, 210 b and the front-facing inside surface 312 of the shaft 302, thus resting the panel on the top surface 236 of the base plate 230.

FIGS. 10 and 11 illustrate one example of an installation (FIG. 10 ) and removal (FIG. 11 ) of a panel in a two-panel assembly. Where an existing panel has already been positioned between the two vertical support posts, a further panel may be inserted generally adjacent to the existing panel. In one example of this arrangement, the right edge of a panel (i.e., right vertical rail 5 b and right upward tab 2 b) is positioned within a vertical support post shared with the left edge (i.e. left vertical rail 5 a and left upward tab 2 a) of an adjacent panel.

FIGS. 12A-D and 13A-B illustrate the positioning of adjacent panels 100, 100 b, showing detail of the connections with the upper tab bracket (FIGS. 12A-D) and baseplate (FIGS. 13A-B). In FIG. 12A, the upper tabs of the adjacent panels abut the tab bracket gusset. In FIG. 12A, left upper tab 2 a on panel 100 is positioned to the left of the upper tab bracket (and, more specifically, abutting the left side of tab gusset 207), while right upper tab 2 d of adjacent panel 100 b is positioned to the right side of the upper tab bracket, such that it abuts the right side of tab gusset 207. In FIGS. 12B-D, the adjacent panels are installed such that they are more significantly overlapping (i.e., where the upper tabs do not necessarily directly engage with the tab gusset). FIG. 12B shows a close up of the tab bracket with adjacent panels overlapping. FIG. 12C shows a perspective view of the panels and vertical support posts of FIG. 12B being assembled, and FIG. 12D shows a close up of the tab bracket of FIG. 12B, fully assembled.

Similarly, FIG. 13A shows the bottom rail 45 b of adjacent panel 100 b being inserted into the base plate channel 212 when the ends of the adjacent panels are closer to the tab gusset of the vertical support post. In this embodiment, bottom rail 45 b of panel 100 b is being positioned within the channel 212 in front of bottom rail 45 of adjacent panel 100, such that bottom rails 45 and 45 b fit into and share the channel space. In FIG. 13B, the adjacent panels are being positioned such that they slightly overlap each other.

FIGS. 14 and 15 show two arrangements of installed panel(s) with the upper tabs assembled with the upper tab bracket for one panel (FIG. 14 ) and adjacent panels (FIG. 15 ). To allow for sharing of adjacent panels on one vertical support post, there must be sufficient space on the post. In particular, a) the bracket pocket 225 in the tab bracket 208 must be sufficiently deep to accommodate the depth of two horizontal rails and two vertical rails of the panels, stacked front to back; and b) the channel 212 in the base plate 230 must be sufficiently deep to accommodate the depth of two vertical rails and two bottom horizontal rails of the panel, stacked front to back (such as also shown in FIG. 13 ). The panel edges (vertical rails) are ideally stacked back to back within the vertical support post to ensure maximal coverage of the area being protected, with minimal or no gaps between the adjacent panels. Further, as the panels are universal within the present assembly, adjacent panels can be positioned back to front (as shown in FIG. 12 ) or front to back (as shown in FIG. 15 ), where the front face of one end of a horizontal rail abuts the back face of an opposite end of an adjacent horizontal rail. Thus, with multiple positioned adjacent panels in a construction site, the panels would alternate front-back-front, etc., to ensure maximal coverage over the protected area. FIG. 16 shows a prospective view of two adjacent panels overlapping in the assembled barrier guardrail assembly.

FIGS. 17A and B show the orientation of two vertical support posts 300, 300 c and corresponding barrier guardrail panels 100, 100 c positioned generally at right angles FIG. 17A (or at angles greater than 90 degrees FIG. 17B) in a corner of a concrete slab 500 having slab edges 502, 504. Vertical support post 300 c comprises a base plate 230 c having panel guide members 210 c, 210 d, base plate gussets 214 d-f, and a retention hole 216 c for similarly allowing the base plate to be securely connected to the concrete slab. Panel 100 c, having top horizontal rail 1 c, is inserted into the vertical support post 300 c (with short segment 220 c of the tab bracket parallel to the slab edge 502). In this embodiment, base plate 230 c of vertical support post 300 c should fit generally perpendicularly in a corner nook created by the base plate 230 of vertical support post 300 and its corresponding barrier guardrail panel 100, ideally producing no gap at the intersection between the end of one panel and the face of an adjacent panel.

The barrier guardrail panel as described herein is thus optimally positioned in the barrier guardrail panel assembly whereby: a) the left and right ends of the bottom of the panels are resting in the respective channels on each of the respective base plates of the respective vertical support posts, between the guide members and the corresponding vertical shafts; b) the left and right ends of the top of the panel (i.e., the top horizontal rail) are positioned within the tab bracket pocket, between the respective long segments of the respective tab brackets on the respective vertical support posts and corresponding shafts; and c) the left and right upper tabs are, respectively, positioned to the left and right of the corresponding tab brackets. Once installed, proper positioning of the upper tabs against the tab gussets of the tab brackets should restrict significant horizontal (left to right) movement of the panel; proper positioning of the bottom horizontal rail of the panel within the base plate channels should restrict significant forward and backward swinging movement of the bottom of the panel; and proper positioning of the top horizontal rail within the tab bracket pocket between the long segment of the tab bracket and the shaft should significantly restrict movement of the panel forward and backward from the top of the panel. However, as stated above, a minimal amount of “give” is permissible in each of these conditions, to allow for slight adjustments of the panel within the barrier guardrail panel assembly, and/or due to expanding and contracting of the metal (e.g. in hot or cold weather) used in the various components of the assembly, but not a high degree of “give” that would cause the panels to be undesirably secured (such as in high-rise building construction applications, where prevalent high winds can cause minimally-secured panels to rattle excessively). Further, the size of the tab gusset 207, if present, should ideally be big enough that when the panel is lowered into position on the vertical support posts, the panel tabs are capable of engaging with the tab gusset to prevent undesirable horizontal movement.

EXAMPLES

To gain a better understanding of the compositions and methods described herein, the following examples are set forth. These examples are for illustrative purposes only, and they should not limit the scope of the present application in any way.

For added safety measures, barrier guardrail assemblies used on constructions sites should be able to withstand loads that the assemblies may encounter during use, and should meet building code and safety standards as applicable.

Components of the barrier guardrail panel assembly as described herein were tested for load tolerances.

Example 1: Testing of Barrier Guardrail Panel Assembly Components

TABLE 1 Results of load on vertical support member and base plate Post Weight (kg) Base Plate Pipe Deflection Welds 100 mm Test Load Bolted Down 130 mm from Passed Base 136 kg with 14 mm vertical with at 136 kg Plate (1.5 factor Set pin 136 kg load load of safety) Plate Deflected 1-5 mm with a load of 136 kg 112 mm Test Load Bolted Down 115 mm from Passed Base 136 kg with 14 mm vertical with at 136 kg Plate (1.5 factor Set pin 136 kg Load load of safety) Tested to 136 kg Load No Deflection

TABLE 2 Results of load on barrier guardrail panel Maximum Load Load Released Final Datum Weight Deflection Deflection Measurement Panel (mm) (kg) (mm) (mm) (mm) Mesh Top 153 136 (1.5 38 4.24 148.68 factor of safety) Middle 485 112 (1.5 82 20 505 No factor of damage safety) Bottom 150 34 (1.5 50 26 124 factor of safety)

The barrier guardrail panel as tested had a 42″ height, with a toeboard height of 5½″ and a maximum ¼″ gap between the panel and ground surface. In this example, the panels weigh approximately 40 lbs, and the posts weigh approximately 8.5 lbs; however, panels weighing 35 lbs may also be used, particularly those made with higher grade, thinner steel. The panel can easily be attached to the post by a single worker.

In the present example, high-grade lightweight galvanized steel was used. This provided advantages over thicker and larger lower grade steel. Many existing steel systems that only use powder coated steel typically see their structural integrity fade quickly.

While regulatory standards vary across North America, the present assembly and its components were tested in consideration of the strictest standards. The testing indicated that the barrier guardrail panel assembly as tested was able to withstand a top rail force of 200 lbs in lateral and vertical directions, multiplied by a factor of safety of 1.5. The assembly was shown to withstand a mid-rail force of 150 lbs in lateral and vertical directions, multiplied by a factor of safety of 1.5. Further, the assembly was shown to withstand a force to the toeboard of 50 lbs in lateral and vertical directions, 

1. A barrier guardrail assembly comprising: a barrier guardrail panel having a top horizontal rail, and a vertical rail on each of left and right edges of the panel, each vertical rail having an upward extending tab positioned generally at the top end of the vertical rails, and which extends beyond a top surface of the horizontal rail; and one or more generally vertical support posts, each comprising a shaft having an upper section and a lower section, the vertical support posts having: a tab bracket in the upper section of the shaft which has an optional gusset member engageable with the upward extending tabs of the panel to restrict undesired horizontal movement; a first segment connected at one end to the shaft and at another end to a downward extending second segment which is engageable with the horizontal rail for retaining the horizontal rail, and a base plate assembly in the lower section having a base plate and one or more vertical tabs on the base plate forming a channel for restraining a bottom edge of the barrier guardrail panel in position when assembled with the vertical support posts.
 2. The barrier guardrail assembly of claim 1, wherein the optional gusset is attached to one or more of the shaft, the first segment, and second segment.
 3. The barrier guardrail assembly of claim 2, wherein the downward extending second segment, gusset and shaft form a bracket pocket for retaining a portion of the top horizontal rail of the barrier guardrail panel.
 4. The barrier guardrail assembly of claim 3, wherein the gusset comprises a rigid horizontal member.
 5. The barrier guardrail assembly of claim 4, wherein the rigid horizontal member extends between the shaft and a vertex formed at the intersection of the first segment and a top end of the downward-extending second segment.
 6. The barrier guardrail assembly of claim 1, wherein the panel comprises a barrier material generally centered on the panel.
 7. The barrier guardrail assembly of claim 6, wherein the barrier material is mesh, closely-spaced wire, a steel plate, expanded steel sheet or plastic netting.
 8. The barrier guardrail assembly of claim 1, wherein the panel comprises a toe board spanning at least a substantial portion of a width of the panel between the two vertical rails.
 9. The barrier guardrail assembly of claim 1, wherein the panel and one or more vertical support posts are made of metal
 10. The barrier guardrail assembly of claim 9, where the metal is treated steel, untreated steel or otherwise reinforced.
 11. The barrier guardrail assembly of claim 10, wherein the treated steel is painted, powder-coated or galvanized.
 12. A barrier guardrail panel for use in a barrier guardrail assembly comprising: a horizontal rail, two vertical rails, each of the vertical rails having an upward extending tab which extends beyond a top surface of the horizontal rail; and a panel barrier material, such as a mesh, extending between the two vertical rails.
 13. A support post for supporting a barrier guardrail panel, the vertical support post comprising: a generally vertical shaft having an upper section and a lower section; a tab bracket in the upper section of the shaft which has an optional tab gusset member which is engageable with upward extending tabs of the barrier guardrail panel to restrict undesired horizontal movement; a first segment connected at one end to the shaft and at another end to a downward extending second segment which is engageable with a horizontal rail on the barrier guardrail panel, for retaining the horizontal rail, and a base plate assembly in the lower section having a base plate and one or more vertical tabs on the base plate forming a channel for restraining a bottom edge of the barrier guardrail panel in position when assembled with the vertical support post.
 14. The support post of claim 13, further comprising one or more gussets on the base plate connected to the lower section of the shaft.
 15. The support post of claim 13, further comprising means for restraining the support post in a fixed position.
 16. The support post of claim 15, wherein the support post is restrained in a concrete slab.
 17. The support post of claim 16, wherein the base plate comprises a passage therethrough for receiving a concrete anchor for bolting in the concrete slab.
 18. The support post of claim 16, wherein the base plate comprises a passage therethrough for receiving a cast-in coil anchor for engaging with an anchor sleeve of a cast-in insert embedded in the concrete slab.
 19. A method of installing the barrier guardrail assembly of claim 1, the method comprising: positioning two of the vertical supports spaced apart from each other at a distance no greater than a width of the barrier guardrail panel between the two vertical rails; placing the top horizontal rail of the barrier guardrail panel within a pocket formed in the top bracket; placing a bottom portion of the barrier guardrail within the channel on the base plate, such that each of the upward extending tabs are, respectively, positioned to the left and right of the corresponding tab brackets. 